Method of Fine Line Space Resolution Lithography for Integrated Circuit Features Using Double Patterning Technology

ABSTRACT

A method includes forming a hard mask over a base material, and forming an I-shaped first opening in the hard mask. The first opening includes two parallel portions and a connecting portion interconnecting the two parallel portions. Spacers are formed on sidewalls of the first opening. The spacers fill an entirety of the connecting portion, wherein a center portion of each of the two parallel portions is unfilled by the spacers. The hard mask is etched to remove a portion of the hard mask and to form a second opening, wherein the second opening is between the two parallel portions of the first opening. The second opening is spaced apart from the two parallel portions of the first opening by the spacers. The first opening and the second opening are then extended down into the base material.

PRIORITY CLAIM AND CROSS-REFERENCE

This application is a divisional of U.S. patent application Ser. No. 13/968,804, entitled “Method of Fine Line Space Resolution Lithography for Integrated Circuit Features Using Double Patterning Technology,” filed on Aug. 16, 2013, which application is incorporated herein by reference.

BACKGROUND

Double patterning is a technology developed for lithography to enhance the feature density. Typically, for forming features of integrated circuits on wafers, the lithography technology is used, which involves applying a photo resist, and defining features on the photo resist. The features in the patterned photo resist are first defined in a lithography mask, and are implemented either by the transparent portions or by the opaque portions in the lithography mask. The features in the patterned photo resist are then transferred to the manufactured features.

With the increasing down-scaling of integrated circuits, the optical proximity effect posts an increasingly greater problem. When two separate features are too close to each other, the optical proximity effect may cause the features to short to each other. To solve such a problem, double patterning technology is introduced. When the double patterning technology is used, the closely located features are separated to two photolithography masks of a same double-patterning mask set, with both masks used to expose the same photo resist, or used to pattern the same hard mask. In each of the masks, the distances between features are increased over the distances between features in the otherwise a single mask, and hence the optical proximity effect is reduced, or substantially eliminated.

The double patterning, however, also suffers from drawbacks. For example, when two features have their lengthwise directions aligned to a same straight line, and the line ends of the features face each other, it is difficult to control the uniformity of the line end space due to the proximity effect and overlay variation. The line widths of the features are also difficult to control, especially when there are other features close to these two features.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the embodiments, and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:

FIGS. 1A through 1C illustrate a top view and cross-sectional views of features formed in a base material; and

FIGS. 2A through 12C are top views, perspective views, and cross-sectional views of intermediate stages in the manufacturing of features in a base material in accordance with some exemplary embodiments.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

The making and using of the embodiments of the disclosure are discussed in detail below. It should be appreciated, however, that the embodiments provide many applicable concepts that can be embodied in a wide variety of specific contexts. The specific embodiments discussed are illustrative, and do not limit the scope of the disclosure.

Features with fine line space and the methods of forming the same are provided in accordance with various exemplary embodiments. The intermediate stages of forming the features are illustrated in accordance with some exemplary embodiments. The variations of the embodiments are discussed. Throughout the various views and illustrative embodiments, like reference numbers are used to designate like elements.

FIG. 1A illustrates a top view of features 20 formed in base material 22. In accordance with some embodiments, base material 22 is a dielectric material such as a low-k dielectric material with a k value lower than 3.8, an extreme low-k dielectric material with a k value lower than about 2.5, or a ultra low-k dielectric material with a k value lower than about 2.0. Base material 22 may also be a semiconductor material such as silicon, a conductive material such as a metal or a metal alloy. Base material 22 may also comprise Phospho-Silicate glass (PSG), Boro-Silicate Glass (BSG), Boron-Doped Phospho-Silicate Glass (BPSG), Tetraethyl Orthosilicate (TEOS) oxide, TiN, SiOC, or any other material in which features of different materials can be formed. Base material 22 may function as an Inter-Metal Dielectric (IMD) or an Inter-Layer Dielectric (ILD) layer.

Features 20, on the other hand, may be conductive features such as metal lines and/or vias, contact plugs, dielectric regions such as Shallow Trench Isolation (STI) regions, polysilicon regions, crystalline silicon regions, or the like. Features 20 and base material 22 may be formed using Chemical Vapor Deposition (CVD), Plasma Enhanced CVD (PECVD), Physical Vapor Deposition (PVD), or the like. In some exemplary embodiments, base material 22 is a dielectric layer (for example, an IMD), and features 20 are metal lines. In alternative embodiments, base material 22 is an ILD, and features 20 are contact plugs.

As shown in FIG. 1A, features 20 include 20A, 20B, 20C, and 20D. Features 20A and 20B are parallel to each other, and are closely located. Features 20C and 20D are located between features 20A and 20B. The lengthwise directions (and the lengthwise center lines) of features 20C and 20D are aligned to the same straight line 21. In accordance with some embodiments, the left ends of features 20A and 20B and the left ends of features 20C and 20D are aligned, as shown in FIG. 1A. In alternative embodiments, the left ends of features 20A and 20B extend farther to the left than the left end of feature 20C. Similarly, the right ends of features 20A and 20B and the right ends of features 20C and 20D may be aligned, as shown in FIG. 1A, or the right ends of features 20A and 20B may be extend farther to the right than the right end of feature 20D. In accordance with some embodiments, line end space 51 between features 20C and 20D is between about 5 nm and about 100 nm. It is appreciated, however, that the values recited throughout the description are merely examples, and may be changed to different values. In the following discussion, it is assumed that features 20A and 20B have the same lengths and widths, and features 20C and 20D have the same lengths and widths, although their lengths and widths may be different from each other.

FIGS. 1B and 1C are cross-sectional views of the structure shown in FIG. 1A, wherein the cross-sectional views are obtained from the vertical plane containing lines A-A and B-B, respectively, in FIG. 1A. As shown in FIGS. 1B and 1C, features 20A, 20B, 20D (and 20C in FIG. 1A) extend into base material 22. Although FIGS. 1B and 1C illustrate that features 20 extend to an intermediate level that is between the top surface and the bottom surface of base material 22, features 20 may also extend from the top surface to the bottom surface of base material 22, wherein an additional layer (not shown) may be underlying base material 22 in these embodiments.

FIGS. 2A through 12C illustrate the top views and cross-sectional views of intermediate stages in the manufacturing of features 20 in base material 22 in accordance with some exemplary embodiments. Referring to FIGS. 2A and 2B, which include a perspective view and a cross-sectional view, respectively, hard masks 24 and 26 are formed over base material 22. In accordance with some embodiments, each of hard masks 24 and 26 comprises a material selected from Si, SiO, SiOC, SiN, metals (such as copper, tungsten, titanium, tantalum, and aluminum), or metal alloys. Each of hard masks 24 and 26 may also comprise a material selected from metal oxides, metal nitrides, and metal oxy-nitrides such as AlO, ALN, AlON, TaN, TiN, and TiO. Although hard masks 24 and 26 may be selected from the same group of candidate materials, hard masks 24 and 26 are formed of different materials so that they have a desirable high etching selectivity, and hence when hard mask 26 is etched, hard mask 24 may be used as an etch stop layer.

The subsequently performed steps shown in FIGS. 3A through 6C are used to form an I-shaped opening in hard mask 26. Referring to FIGS. 3A and 3B, which include a perspective view and a cross-sectional view, respectively, photo resist 28 is formed over hard mask 26, for example, using spin coating. Photo resist 28 is then patterned to form opening 30, through which hard mask 26 is exposed. Length L1 of opening 30 may be in the range between about 30 nm and about 1,000 nm, and width W1 of opening 30 may be in the range between about 5 nm and about 100 nm. Length L1 and width W1, however, is related to the technology generation for forming the integrated circuits, and may have different values.

The exposed portion of hard mask 26 is then etched using the patterned photo resist 28 as an etching mask, so that opening 30 extend into hard mask 26. Hard mask 24 is used as an etch stop layer during the etching. Photo resist 28 is then removed. The resulting structure is shown in FIGS. 4A, 4B, and 4C, which illustrate that the pattern of opening 30 is transferred into hard mask 26. FIG. 4B is a top view of the structure in FIG. 4A. FIG. 4C is a cross-sectional view of the structure in FIGS. 4A and 4B, wherein the cross-sectional view is obtained from the plane containing line A-A in FIG. 4B.

Next, referring to FIGS. 5A, 5B, 5C, and 5D, photo resist 32 is formed and patterned, forming openings 34 in photo resist 32. FIGS. 5A and 5B illustrate a view and a top view, respectively. The cross-sectional views in FIGS. 5C and 5D are obtained from the planes containing lines A-A and B-B, respectively, in FIG. 5B. As shown in FIGS. 5A and 5B, openings 34 have lengthwise directions parallel to each other. Length L2 and width W2 of openings 34 are selected to be greater than the length L3 and the width W3, respectively, of features 20A and 20B (FIG. 1A), by a difference, wherein the details of the difference is discussed in detailed in subsequent paragraphs.

As shown in FIGS. 5A and 5B, photo resist 32 covers and fills a middle portion of opening 30, while the opposite end portions of opening 30 are not covered, and are exposed to opening 34, as also shown in FIG. 5C.

Next, hard mask 26 is further etched. In the etching, photo resist 32 is used as an etching mask, and hard mask 24 is used as an etch stop layer, so that openings 34 extend into hard mask 26. Photo resist 32 is then removed. The resulting structures are shown in FIGS. 6A, 6B, and 6C, which illustrate a top view and two cross-sectional views. FIGS. 6A illustrates a perspective view. The cross-sectional views in FIGS. 6B and 6C are obtained from the planes containing lines A-A and B-B, respectively, in FIG. 6A. Openings 30 and 34 in combination form an I-shaped opening, which is sometimes referred to as opening 36, as shown in FIG. 6A. I-shaped opening 36 include two parallel openings 34, with opening 30 connecting parallel openings 34.

Referring to FIGS. 7A, 7B, and 7C, spacer layer 38 is blanket formed over the structure in FIGS. 6A through 6C. FIGS. 7A illustrates a perspective view. The cross-sectional views in FIGS. 7B and 7C are obtained from the planes containing lines A-A and B-B, respectively, in FIG. 7A. The planes of FIGS. 7B and 7C are also the same planes in FIGS. 6B and 6C, respectively. The material of spacer layer 38 may be selected from the same group of candidate materials for forming hard masks 24 and 26. Alternatively, the material of spacer layer 38 may be selected from a different group of materials. For example, the material of spacer layer 38 may be selected from Si, SiO, SiN, metals and metal alloys. The material of spacer layer 38 may also be selected from metal oxides, metal nitrides, and metal oxy-nitrides such as AlO, AlN, AlON, TaN, TiN, TiO, or the like. Furthermore, although may be selected from the same pool, the material of spacer layer 38 is different from the materials of hard masks 24 and 26, so that they may have a desirable etching selectivity, and hence when spacer layer 38 is etched, hard masks 24 and 26 are not be etched if desirable, and hard masks 24 and 26 are used as an etch stop layer when spacer layer 38 is etched.

As shown in FIGS. 7A, 7B, and 7C, spacer layer 38 may be formed as a conformal layer, with the thickness T1 (FIG. 7C) of its horizontal portions and the thickness T2 of its vertical portions close to each other, for example, with a difference smaller than about 20 percent of thickness T1.

An anisotropic etching is then performed to remove the horizontal portions of spacer layer 38, while the vertical portions of spacer layers 38 remain, and are referred to as spacers 40 hereinafter. In alternative embodiments, a Chemical Mechanical Polish (CMP) is performed to remove portions of spacer layer 38 over hard mask layer 26. The result structure is shown in FIGS. 8A, 8B, 8C, and 8D. FIGS. 8A and 8B illustrate a perspective view and a top view, respectively. The cross-sectional views in FIGS. 8C and 8D are obtained from the planes containing lines A-A and B-B, respectively, in FIG. 8B. The remaining vertical portions of spacer layer 38 form spacers 40, as shown in FIGS. 8A, 8B, 8C, and 8D.

When spacer layer 38 (FIG. 7C) is formed, thickness T2 of spacer layer 38 is also equal to or greater than a half of width W1 (FIG. 8B) of opening 30. As a result, the sidewall (vertical) portions of spacer layer 38, which sidewall portions are on opposite sidewalls of opening 30, merge with each other, as shown in FIGS. 8A and 8B. Hence, spacers 40 fill an entirety of opening 30. On the other hand, as shown in FIG. 8B, widths W2 of openings 34 are greater than two times thickness T2, so that each of openings 34 has a center portion 34′ remaining not filled by spacers 40. Hard mask 24 is exposed through openings 34′. Width W3 of the openings 34′ is the desirable width W3 of features 20A and 20B, as shown in FIG. 1A. Similarly, length L3 of openings 34′ is the desirable length of features 20A and 20B, as shown in FIG. 1A. Accordingly, length L3 and width W3 may be achieved by adjusting length L2 and W2 (FIG. 5A) and thickness T2 (FIG. 7C).

FIGS. 9A through 10C illustrate the steps for defining the size and locations of features 20C and 20D (FIG. 1). Referring to FIGS. 9A, 9B, 9C, and 9D, photo resist 42 is formed and patterned, forming opening 44 in photo resist 42. FIGS. 9A and 9B illustrate a perspective view and a top view, respectively. The cross-sectional views in FIGS. 9C and 9D are obtained from the planes containing lines A-A and B-B, respectively, in FIG. 9B. As shown in FIG. 9B, portion 40A of spacers 40, which portion 40A is filled into opening 30 (FIG. 5B) is exposed through opening 44. As shown in FIG. 9A, some portions 26A of hard mask 26, which portions 26A are between openings 34′ (FIG. 9B), are also exposed to opening 44.

Next, the exposed hard mask portions 26A are etched using photo resist 42 as an etching mask. The etching also stops on hard mask 24 and spacers 40. Photo resist 42 is then removed. FIG. 10A illustrates a perspective view of the resulting structure. The cross-sectional views in FIGS. 10B and 10C are obtained from the planes containing lines A-A and B-B, respectively, in FIG. 10A. As a result of the etching, openings 46 are formed in, and surrounded by, hard mask 26 and spacers 40. Furthermore, as shown in FIG. 10A, there exist two openings 34′, and two openings 46 between openings 34′, wherein openings 34′ and openings 46 in combination have the same layout and sizes as features 20 in FIG. 1A.

FIGS. 11A, 11B, and 11C illustrate the transferring of the patterns of openings 34′ and openings 46 to underlying hard mask 24 and base material 22. FIGS. 11A and 11B illustrate a perspective view and a top view, respectively, of the resulting structure. The cross-sectional views in FIGS. 11C and 11D are obtained from the planes containing lines A-A and B-B, respectively, in FIG. 11B. First, hard mask 26 and spacers 40 in FIGS. 10A, 10B, and 10C are in combination used as an etching mask to etch the underlying hard mask 24, so that openings 34′ and 46 extend down into hard mask 24. Hard mask 26 may then be removed in some embodiments. In alternative embodiments, hard mask 26 may be left un-removed.

As also shown in FIGS. 11A, 11B, and 11C, hard mask 24 (and possibly the un-removed spacers 40) is used as an etching mask to etch base material 22, so that openings 34′ and 46 extend into base material 22. Next, hard mask 24 and spacers 40 are removed, and the resulting structure is shown in FIGS. 12A, 12B, and 12C, which include a top view and cross-sectional views. In a subsequent step, openings 34′ and 46 are filled with features 20, and the resulting structure is shown in FIGS. 1A, 1B, and 1C. The formation of features 20A, 20B, 20C, and 20D may include blanket depositing a material that is the same as the material of features 20, and performing a planarization such as a Chemical Mechanical Polish (CMP) to remove excess portions of the material over base material 22. The remaining un-removed material form features 20. Features 20A and 20B (FIGS. 1A, 1B, and 1C) fill openings 34′ (FIG. 12A), and features 20C and 20D (FIGS. 1A, 1B, and 1C) fill openings 46 (FIG. 12A).

Referring to FIG. 1A, features 20A and 20B comprise major portion 20A1 and 20B1, respectively, which may have rectangular shapes. The edges 20A3 and 20B3 of the major portions are parallel to each other, and are parallel to straight line 21. Features 20A and 20B further include tip portions 20A2 and 20B2, respectively, which are connected to the respective major portions 20A1 and 20B1. Tip portions 20A2 and 20B2 are the result of the shape of spacers 40 (FIG. 8B). Referring back to FIG. 1A, tip portions 20A2 and 20B2 are aligned to the center of the space between the ends of features 20C and 20D. Each of the tip portions 20A2 and 20B2 has gradually and continuously reduced widths, wherein the widths of the tip portions are measured in a direction parallel to edges 20A3 and 20B3.

The embodiments of the present disclosure have some advantageous features. The line end space of features 20C and 20D are defined by the step in FIG. 4A, and features 20C and 20D are formed simultaneously. Therefore, there is no double patterning overlay issue. The variation in the line end space is thus minimized. Furthermore, the line end space of features 20C and 20D may be very small since is equal to the minimum size defined by the respective lithography technology. As a comparison, in conventional methods, since features 20C and 20D are very close to each other, double patterning was used to form features 20C and 20D. Furthermore, in conventional methods, since features 20C and 20D are close to features 20A and 20B, sometimes triple patterning is needed. In the triple patterning, features 20A and 20B are formed using a first photolithography process, feature 20C is formed using a second photolithography process, and feature 20D is formed using a third photolithography process. Therefore, severe overlay issue may occur in the conventional triple patterning technology.

In accordance with some embodiments, a method includes forming a hard mask over a base material, and forming an I-shaped first opening in the hard mask. The first opening includes two parallel portions and a connecting portion interconnecting the two parallel portions. Spacers are formed on sidewalls of the first opening. The spacers fill an entirety of the connecting portion, wherein a center portion of each of the two parallel portions is unfilled by the spacers. The hard mask is etched to remove a portion of the hard mask and to form a second opening, wherein the second opening is between the two parallel portions of the first opening. The second opening is spaced apart from the two parallel portions of the first opening by the spacers. The first opening and the second opening are then extended down into the base material.

In accordance with other embodiments, a method includes forming a first hard mask over a base material, forming a second hard mask over the first hard mask, performing a first etching step on the second hard mask to form a first opening, and performing a second etching step on the second hard mask to form a second opening and a third opening parallel to each other. Opposite ends of the first opening are connected to the second opening and the third opening to form an I-shaped opening. A blanket spacer layer is formed over the second hard mask, wherein the blanket spacer layer extends into the I-shaped opening. Portions of the blanket spacer layer over the second hard mask are removed, with remaining portions of the blanket spacer layer forming spacers. The spacers comprise a connecting portion filling an entirety of a portion of the first opening that connects the second opening and the third opening. Center portions of the second opening and the third opening are unfilled by the spacers. The second hard mask is then etched to remove portions of the second hard mask to form a fourth opening and a fifth opening in the second hard mask. The fourth opening and the fifth opening are on opposite sides of the connecting portion of the spacers, and are between the second opening and the third opening.

In accordance with yet other embodiments, an integrated circuit structure includes a base material, and a first feature and a second feature extending into the base material. The first feature and the second feature have lengthwise directions aligned to a straight line. The first feature and the second feature are spaced apart from each other by an intermediate portion of the base material. A third feature extends into the base material, wherein the first feature, the second feature, and the third feature are formed of a same material. The third feature includes a major portion having a straight edge parallel to the lengthwise directions of the first feature and the second feature, and a tip portion connected to the major portion, wherein the tip portion is aligned to a middle line of the intermediate portion of the base material.

Although the embodiments and their advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the embodiments as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, and composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed, that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the disclosure. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps. In addition, each claim constitutes a separate embodiment, and the combination of various claims and embodiments are within the scope of the disclosure. 

What is claimed is:
 1. An integrated circuit structure comprising: a base material; a first feature and a second feature extending into the base material, wherein the first feature and the second feature have lengthwise directions aligned to a straight line, and wherein the first feature and the second feature are spaced apart from each other by an intermediate portion of the base material; and a third feature extending into the base material, wherein the first feature, the second feature, and the third feature are formed of a same material, and wherein the third feature comprises: a major portion having a straight edge parallel to the lengthwise directions of the first feature and the second feature; and a tip portion connected to the major portion, wherein the tip portion is aligned to a middle line of the intermediate portion of the base material.
 2. The integrated circuit structure of claim 1, wherein the tip portion is closer to the intermediate portion of the base material than the major portion.
 3. The integrated circuit structure of claim 1, wherein the tip portion has gradually and continuously reduced widths.
 4. The integrated circuit structure of claim 1 further comprising: a fourth feature extending into the base material and formed of a same material as the first feature, wherein the first feature and the second feature are between the third feature and the fourth feature, and wherein the fourth feature comprises: an additional major portion having an additional straight edge parallel to the lengthwise directions of the first feature and the second feature; and an additional tip portion connected to the additional major portion, wherein the additional tip portion is aligned to the middle line of the intermediate portion of the base material.
 5. The integrated circuit structure of claim 1, wherein the base material is a dielectric material, wherein the base material forms an inter-metal dielectric, and wherein the first feature, the second feature, and the third feature are metal lines.
 6. The integrated circuit structure of claim 1, wherein the base material is a dielectric material, wherein the base material forms an inter-layer dielectric, and wherein the first feature, the second feature, and the third feature are contact plugs.
 7. The integrated circuit structure of claim 1, wherein the first feature comprises a dielectric material.
 8. A semiconductor device comprising: a substrate; a first opening within the substrate, wherein the first opening comprises: a first side of the first opening, wherein the first side of the first opening is straight; a second side of the first opening, wherein the second side of the first opening is straight; a third side of the first opening, wherein the third side of the first opening is straight; a fourth side of the first opening, wherein the fourth side of the first opening is at least partially curved and forms a first pointed shape; a second opening within the substrate, wherein the second opening comprises: a first side of the second opening, wherein the first side of the second opening is straight; a second side of the second opening, wherein the second side of the second opening is straight; a third side of the second opening, wherein the third side of the second opening is straight; a fourth side of the second opening, wherein the fourth side of the second opening is at least partially curved and forms a second pointed shape, wherein the second pointed shape points towards the first pointed shape.
 9. The semiconductor device of claim 8, further comprising a third opening located between the first opening and the second opening; and a fourth opening located between the first opening and the second opening, wherein the third opening has a first longitudinal axis, the fourth opening has a second longitudinal axis, and the first longitudinal axis is aligned with the second longitudinal axis.
 10. The semiconductor device of claim 9, wherein the third opening is rectangular is shape.
 11. The semiconductor device of claim 9, wherein the third opening and the fourth opening are outside of a region located between the first pointed shape and the second pointed shape.
 12. The semiconductor device of claim 8, wherein the substrate comprises a dielectric material.
 13. The semiconductor device of claim 12, further comprising a conductive material filling the first opening and the second opening.
 14. The semiconductor device of claim 8, further comprising a dielectric material filling the first opening and the second opening.
 15. A semiconductor device comprising: a dielectric material over a substrate; a first conductive feature within the dielectric material, the first conductive feature comprising: a first side, wherein the first side is straight; and a second side opposite the first side, wherein the second side has a variable distance from the first side; a second conductive feature within the dielectric material, the second conductive feature comprising: a third side, wherein the third side is straight; and a fourth side opposite the third side and facing the second side, wherein the third side has a variable distance from the third side, and wherein a first point of the second side that is located furthest from the first side is aligned with a second point of the fourth side that is located furthest from the third side.
 16. The semiconductor device of claim 15, wherein the first conductive feature is a contact.
 17. The semiconductor device of claim 15, wherein the first conductive feature is a conductive line.
 18. The semiconductor device of claim 15, wherein the dielectric material extends from the first point to the second point.
 19. The semiconductor device of claim 15, further comprising a third conductive feature located between the second side and the fourth side.
 20. The semiconductor device of claim 19, further comprising a fourth conductive feature located between the second side and the fourth side, wherein the fourth conductive feature is separated from the third conductive feature by the dielectric material. 